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Rules and *Rules of Thumb for Duct Systems

Educated guesses and past experience with trial and error apply when using rules of thumb. For the same temperature in all rooms upstairs and down, equipment
that can last 30+ years, and performs at its rated efficiency and capacity, then follow the procedures in the ACCA Manuals: J, S, D and T. Otherwise read on

Designing Heat Pump duct systems with correct velocity and low restriction
AHU Supply & Return connection - properly sized; minimize the System Effect, assure Static Regain and allow even airflow thru coils
Size the 1st supply fitting or duct to the dimensions of the blower outlet, not to the extents of the AHU or fan/coil cabinet.
1st supply fitting or ducts length should be 2.5 times the blower outlets equivalent diameter minus the heater section, or *24.
Size the 1st return fitting or duct to a length *at least as long, if not longer, than the width of the AHU or fan/coil base.
Metal Supply Trunks - properly sized supply trunks allow the rated airflow and reduce the power consumed by the blower
Use a sheet metal duct calculator at a friction rate of *0.1wc or less to size each metal trunk duct. (0.06wc to be safe)
Check the velocity of the air and increase the duct size if the velocity is greater than 900 fpm. 700 fpm is recommended for low
restriction and noise. Size for *400 cfm per nominal ton, convert round sizes to their rectangular equivalent as needed.
*Use long and radiused fittings instead of short or mitered fittings wherever possible.
8up to 245 cfm

1.5 ton - 12 or 10 and an 8

4 ton - 18 or two 14 or two 12 and one 10

2 ton - 14 or two 10

5 ton - 20 or two 16 or two 12 and one 14
10 up to 440 cfm
12 up to 715 cfm

2.5 ton - 16 or 12 and 10
14 up to 975 cfm

3 ton - 16 or two 12 or three 10
16 up to 1270 cfm

3.5 ton - 18 or 12 and 14 or two 10 and one 12
Flexible Supply Runs & Registers properly sized with adjustable dampers; allow quiet draftless airflow that can be balanced
Use a flex duct calculator at a friction rate of *0.1wc or less (or a metal ductulator at *0.05wc or less) to size flex duct.
*Assume 66 cfm for 6 flex runs, at 4% compression, with a 4x10 floor or a 6x10 ceiling register. A nominal 2 ton system would
have 12 to 13 outlets. Use straight boots with an elbow wherever possible. Choose registers over diffusers with heat pumps.
*Assume 21 cfm for 4 flex runs. Use in bathrooms, large closets etc. that have an exterior wall and minimal window area.
Flexible duct should be stretched tight and supported to prevent future sagging. Avoid crimping and sharp turns.
*Distribute one for each exterior opening and/or outside wall. *1 or *2 per room unless very large or more than 3 exposures.
*4 or more for sunrooms and rooms over garages. Allow access for an additional run just in case.
Avoid take-offs within *18 downstream of elbows, transitions etc. they cause uneven air pressures in the trunk.
Use take off dampers to control the amount of airflow. Adjusting the register may increase noise and reduce room air mixing.
Use the manufactures engineering data to size registers for an unobtrusive throw without stratification. 700 fpm max.
Flexible Return Runs - properly sized flex ducts allow the rated airflow and may reduce blower power consumption, stretch it tight!
Use a flex duct calculator at a friction rate of *0.1wc or less (or a metal ductulator at *0.05wc or less) to size flex duct.
Use the duct calculator to find the velocity of the air at the size determined by the friction rate and increase the size if the velocity
is greater than 700 fpm. 600 fpm is recommended for low restriction and noise.
Size to *400 cfm per nominal ton. The following sizes assume no more than 4% flexible duct compression.
8 up to 157 cfm

1.5 ton - 14 or 12 and a 8

4 ton - 16 and a 14 or two 14 and one 8
10 up to 297 cfm

2 ton - 16 or 12 and a 10

5 ton - two 16 or two 14 and one 12
12 up to 502 cfm

2.5 ton - 16 or 14 and a 10
14 up to 781 cfm

3 ton - 14 and a 12 or three 12
16 up to 1015 cfm

3.5 ton - 16 and a 12 or two 14 or three 12
Filter Grilles - properly sized filter grilles are quiet, permit rated airflow, and allow standard disposable filters to trap small particulate
Size Filter Grilles to a face velocity no greater than 400 fpm. Standard air filters lose effectiveness over 400 fpm.
Use the equation; CFM FPM = Ak to find the required effective area and match it to the Ak rating of the grille.

10x6 (Ak 0.28) up to 111 cfm

14x18 (Ak 1.14 ) up to 457

16x25 (Ak 1.80 ) up to 720 cfm

12x12 (Ak 0.66 ) up to 263 cfm

14x20 (Ak 1.27 ) up to 507 cfm

20x20 (Ak 1.80 ) up to 720 cfm

14x14 (Ak 0.89 ) up to 357 cfm

18x18 (Ak 1.46 ) up to 585 cfm

14x30 (Ak 1.89 ) up to 756 cfm

12x18 (Ak 0.98 ) up to 392 cfm

20x16 (Ak 1.46 ) up to 585 cfm

24x20 (Ak 2.16 ) up to 862 cfm

14x16 (Ak 1.02 ) up to 407 cfm

24x14 (Ak 1.52 ) up to 607 cfm

25x20 (Ak 2.24 ) up to 898 cfm

20x12 (Ak 1.10 ) up to 440 cfm

16x24 (Ak 1.73 ) up to 692 cfm

20x30 (Ak 2.96 ) up to 1074 cfm
Flat Grilles - properly sized flat grilles are quiet, allow the rated airflow and may reduce the power consumed by the blower
Size Flat Return Air Grilles to a face velocity no greater than 500 fpm. Orient grille to minimize view of duct interior.

8x8 (Ak 0.30) up to 148 cfm

12x20 (Ak 1.09 ) up to 544 cfm

20x20 (Ak 1.80 ) up to 900 cfm

12x8 (Ak 0.44 ) up to 221 cfm

14x18 (Ak 1.14 ) up to 571 cfm

30x14 (Ak 1.89 ) up to 945 cfm

10x10 (Ak 0.46 ) up to 230 cfm

6x16 (Ak 1.16 ) up to 580 cfm

20x24 (Ak 2.16 ) up to 1078 cfm

12x12 (Ak 0.66 ) up to 329 cfm

8x18 (Ak 1.46 ) up to 732 cfm

16x30 (Ak 2.18 ) up to 1088 cfm

Effective Area data for Hart & Cooley model 673 Return Air Filter Grille and 672 Flat Return Air Grille. Supply registers are model 682.

WaynePendergast@comcast.net
10/19/2014